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Sandia 2014 Wind Turbine Blade Workshop- Coffey

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Sandia 2014 Wind Turbine Blade Workshop- Coffey

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Sandia 2014 Wind Turbine Blade Workshop- Coffey

  1. 1. Blade Reliability Case Study Sandia Wind Turbine Blade Workshop August 26, 2014 David Coffey
  2. 2. Overview • Snapshot of Iberdrola Renewables • Overview of blade failure data • Failure modes & repair rates • Examples of carbon spar damage • Examples of large crack repair • Conclusions • Improvement Goals Aug 26, 2014 David Coffey 2
  3. 3. 3 Iberdrola Renewables - North America Iberdrola Renewables develops, owns and operates wind plants throughout the U.S. • 3000+ turbines • 56 wind farms • 18 states • 6+ GW capacity • 6 different OEMs • Rotor dia. 47-102 m O & M Engineering: • Performance & Reliability • Continuous Improvement • Root cause analysis • Reliability centered maintenance • Failure rate projections • Repair specifications Aug 26, 2014 David Coffey
  4. 4. 4 Snapshot of Iberdrola Renewables Fleet Aug 26, 2014 David Coffey
  5. 5. Blade Reliability Aug 26, 2014 David Coffey 5 “Repair required” blade damages by year: • 7+ years • ~ 2600 reports • includes end of warranty inspections, FM, operations etc. Typical types of damage: • Lightning • Cracks • Impact damage • Surface/gel coat • LE erosion
  6. 6. Blade Reliability Aug 26, 2014 David Coffey 6 Top 5 damage types: 1. Lightning 2. LE Erosion - Light/medium/heavy 3. Cracks 4. Gel coat damage 5. “Undetermined” includes: • Lightning • Ice • Moisture intrusion Damages can be broken down further by location on blade Top 9 represent 80%
  7. 7. Blade Reliability Aug 26, 2014 David Coffey 7 • 94% reported damage is repairable • Repair rates for lightning have improved • Carbon spar damage is still problematic • Structural cracks are less likely to be repairable
  8. 8. Examples of carbon spar lightning damage Repairable today Repairable tomorrow? Aug 26, 2014 David Coffey 8
  9. 9. 9 Examples of large crack repair Aug 26, 2014 David Coffey Upper shell Lower shell • Testing feasibility of large crack repairs • Will the repairs last? • Is it economical?
  10. 10. Blade Reliability Conclusions: 1. Overall blade damage rates are higher than expected 2. Lightning damage, LE erosion, Gel coat damage account for 80% of damage reported 3. 94% total repair rate for all blade damages – 6% replacement rate drives cost of ownership 4. Ongoing cost of ownership for carbon spar blades is higher than other blade types – Actively seeking improved protection and repair options. Aug 26, 2014 David Coffey 10
  11. 11. Improvement Goals: 1. Blade damage – Improved data reporting – standard method of damage categorization – Continue to refine and improve damage reporting data base • Clear and consistent criteria for run vs. stop decisions • Clarify repair criteria – Up tower repair – types and severity – Ground repair – economic feasibility of repairs 2. Lightning protection: – Design and test standards • Improvements needed to IEC61400-24 lightning protection efficiency calculations – LPS system enhancements 3. Large crack repair 4. Carbon spar repair Aug 26, 2014 David Coffey 11
  12. 12. Thank You! David Coffey 12

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